Methods for making a gasket with a pliable resilient body with a perimeter having characteristics different than the body

ABSTRACT

A single piece gasket is disclosed having a skeletal member, typically metallic, and a pliable body. The pliable body includes a first portion having a first firmness and a second perimeter portion have a firmer consistency. When such a composite body is placed under compression, the perimeter will tend to limit the flow of the softer inner material past the firmer perimeter region or portion of the gasket. In this manner, creep or overrun of the less firm portion material will be reduced.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/646,888, filed Jul. 11, 2017, which is a continuation of and claimspriority to U.S. patent application Ser. No. 13/469,603, filed May 11,2012, now issued as U.S. Pat. No. 9,701,388, which claims priority toU.S. Patent Application No. 61/484,879, filed May 11, 2011. Thesepriority applications are herein incorporated by reference as well asU.S. Pat. Nos. 6,530,577; 6,695,320; and 7,229,516.

FIELD OF THE INVENTION

Gaskets, including aircraft gaskets, having a perimeter of greaterfirmness than the non-perimeter, more tacky portion thereof.

BACKGROUND OF THE INVENTION

Gaskets provide a mechanical seal that fills the space between twomating surfaces. They may be provided to prevent leakage from or intothe pieces under compression. Gaskets typically can allow less thanperfect mating surfaces on machine parts where they can fillirregularities. Gaskets are commonly produced from cutting sheetmaterials, such as gasket paper, rubber, silicon, metal, cork, felt,neoprene, nitrile rubber, fiberglass or plastic polymer, such aspolychloro, trifloro ethylene.

Pre-cured polyurethane and antenna gaskets have been provided withaluminum skeletal carrier die cut to fit the workpiece, such as anaircraft antenna. The polyurethane provides an effective environmentalsealant. It also demonstrates excellent cohesion after installation andprovides a high degree of environmental protection, still allowing foreasy removal of the workpiece.

Polyurethane provides a non-hazardous seal with no silicon oil residuebefore, during or after installation or removal. Moreover, polyurethaneis not problematic with paint adhesion or preparation and there is noperipheral silicon contamination. Polyurethane provides a positivemoisture barrier for easy workpiece removal and provides noise andvibration dampening.

In some applications, however, some polyurethane may creep undercompression creating an overrun outside the gasket area. This maysometimes require manual removal.

SUMMARY OF THE INVENTION

Various embodiments of Applicants' device are enclosed, which feature asingle piece gasket having a skeletal member having a pliable body,wherein the pliable body typically includes a first portion having afirst firmness and a second, perimeter portion, having a firmerconsistency. When such a composite body is placed under compression, theperimeter will tend to limit the flow of the softer inner material pastthe firmer perimeter region or portion of the gasket. In this manner,creep or overrun of the less firm first portion material will besubstantially reduced or eliminated.

Thus, in one version of Applicants' embodiment, a dual firmness body,such as a polyurethane body, will have a first firmness of a firstportion of the body and a firmer consistency and resistant tocompression over a perimeter or second region, which second or perimeterregion typically conforms to the outer edges of the workpiece.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational cutaway view of one embodiment of prior artgaskets as taught by the following U.S. Pat. Nos. 7,229,516; 6,695,320;and 6,530,577, all of which are incorporated herein by reference.

FIG. 2 is an exploded side elevational view of a prior art gasket, suchas that in FIG. 1 used under compression between a workpiece WP and abase.

FIG. 3 is the illustration of FIG. 2, with the gasket in place and undercompression between the workpiece and the base, illustrating overrun“OR” of some of the gasket material where it has seeped out past theedge of the workpiece outer perimeter.

FIG. 4A is a side, cutaway elevational view of a first embodiment ofApplicants' dual firmness gasket having a skeletal member.

FIG. 4B illustrates a side elevational view in cross-section of firstembodiment of Applicants' new gasket and the manner in which it alignswith the workpiece outer perimeter prior to compression between theworkpiece and the base.

FIG. 4C illustrates the first embodiment in an “overcut application ofApplicants' improved gasket in a side elevational view illustrating therelationship between the firmer perimeter of the gasket and theperimeter of the workpiece prior to compression, wherein the outerperimeter of the gasket extends slightly beyond the outer perimeter ofthe workpiece.

FIG. 4D illustrates the first embodiment in an “undercut” application ofApplicants' improved gasket wherein the firmer outer perimeter of thegasket is undercut and wherein prior to compression the outer perimeterof the workpiece extends slightly beyond the outer perimeter of thegasket.

FIGS. 4E and 4F illustrate side elevational views of an embodiment ofApplicants' invention having a separate perimeter member, engageableafter attachment of workpiece and gasket to the base.

FIG. 5 illustrates a side elevational view of a first embodiment ofApplicants' improved gasket as set forth in FIGS. 4A and 4B, undercompression between a workpiece and a base, illustrating the manner inwhich the firmer outer perimeter reduces seepage or overrun along theouter perimeter of the workpiece.

FIG. 6 illustrates a side cutaway perspective view of a secondembodiment of Applicants' improved gasket.

FIG. 7 is an illustration of the embodiment of FIG. 6 under compressionbetween a workpiece and a base.

FIG. 8 illustrates a third embodiment of Applicants' improved gasket inside cross-sectional elevational view.

FIG. 9 illustrates a cross-sectional view of the gasket set forth inFIG. 8, under compression showing the edge of a workpiece and the edgeof a base.

FIG. 10 is a fourth embodiment of Applicants' present invention incross-sectional elevational view.

FIG. 11 illustrates the embodiment of FIG. 10 under compression betweena workpiece and a base, along the edge of the workpiece.

FIG. 12 illustrates a fifth embodiment of Applicants' improved gasket incross-sectional elevational view.

FIG. 13 illustrates the embodiment of FIG. 12 in cross-sectionalelevational view under compression at or near the perimeter of aworkpiece.

FIG. 14 illustrates a sixth embodiment of Applicants' present inventionin cross-sectional side elevational view.

FIG. 15 illustrates the gasket of FIG. 14 under compression between theworkpiece and a base, near the edge of the workpiece.

FIGS. 16A and 16B illustrate in cross-sectional view a manner ofmanufacturing the first embodiment of Applicants' device.

FIGS. 17A and 17B illustrate in cross-sectional elevational view amethod of making the second embodiment of Applicants' improved gasket.

FIGS. 18A and 18B illustrate in cross-sectional view, a method of makingthe third embodiment of Applicants' present invention.

FIGS. 19A and 19B illustrate in cross-sectional side elevation, a methodof making the fourth embodiment of Applicants' gasket.

FIGS. 20A and 20B illustrate a method of making the fifth embodiment ofApplicants' improved gasket.

FIGS. 21A and 21B illustrate a method of making the sixth embodiment ofApplicants' improved gasket.

FIG. 22 illustrates an exposed skeleton, beyond the body of the gasketbeing made by the use of a mold.

FIG. 23 illustrates the cured, exposed skeleton gasket made by the stepillustrated in FIG. 22 aligned with a workpiece which will be applied toa base.

FIG. 24 illustrates the gasket of FIGS. 22 and 23, under compressionbetween the workpiece and base.

FIG. 24A illustrates a gasket under compression between the workpieceand base, but leaving an exposed skeleton and a gap.

FIG. 24B illustrates a gasket under compression leaving a gap, but noexposed skeleton.

FIG. 25 illustrates the application of a bead to the embodiment of FIG.24.

FIG. 25A illustrates the application of a bead to the embodiment of FIG.24A.

FIG. 25B illustrates the application of a bead to the embodiment of FIG.24B.

FIG. 26 illustrates a bead being shaped in an optional step, whichshaping may be applied to any of the foregoing gap. gapless, exposed,non-exposed skeleton embodiments.

FIG. 27 illustrates the cured bead integral with the body and adjacent,typically contacting the workpiece and base.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 4A thru 4D illustrate a first embodiment 10 a of Applicants'improved gasket. Gasket 10 a, like the embodiments that follow, willprovide for a workpiece WP to Base mechanical seal over substantiallythe entire surface of the workpiece and the base beneath the workpiece.

The pre-compression thickness of the embodiments set forth herein may beabout 55 mil (range about 25-100 mil). Gasket 10 a comprises of aresilient body 12, typically made from pre-cured polyurethane gasketmaterial, such as KBS, Fort Worth, Texas, as disclosed in the patentsthat are incorporated by reference. Body 12 is seen to have a firstportion 14 having a first firmness, such as a firmness between about 75and about 150 (measured with a 37.5 g half cone penetrometer). Thesecond firmer perimeter portion 16 is seen to comprise the outerperimeter of the gasket, which generally mimics the shape of the outerperimeter of the workpiece, in which second firmer perimeter portion 16may have a durometer hardness “00” of between about 15 and about 75. Theperimeter portion may be made from HT3326-5 and the body or innerportion may be made from a mix of P-1011 and U-1010. This will provide agasket within the firmness range set forth in this paragraph.

It is seen that the relationship of the first portion to the secondportion is one of typically close, adjacent, contiguous integral and/orintimate relation of one portion with respect to the other along commonface 23. That is to say, they lay adjacent one another and indeed mayintermingle one portion to the other at least close to the boundaryportion or common face 23 between the first and second portions.Moreover, it is seen with reference to FIGS. 6, 8, 10, 12, and 14 that,while the first, less firm portion 14 may be typically tabular innature, the second firmer perimeter portion 16 may take a number ofcross-sectional configurations. These configurations may be varied,first to provide an effective seal, under compression, against overrunof the first portion outside the boundaries generally defined by thesecond perimeter portion, as well as to provide an effective and anaesthetically pleasing mechanical seal. In some cases, a bead portion,or more generally, a formed portion extending beyond the perimeter ofthe workpiece (see, for example, the detail view of FIG. 7) is provided.

That is to say, Applicants provide for a number of cross-sectionalconfigurations to the second, firmer perimeter portion 16, which aredesigned to provide both an effective seal and/or a visually pleasingperimeter. This is achieved, in part, by providing a second material atan outer perimeter having a firmer consistency, while beingsubstantially integral with the first portion 14.

Some embodiments of Applicants' gaskets disclosed herein have configuredsecond portions 16 as more generally described hereinbelow. The shapesmay generally be described as: 10 a tabular; 10 b tabular (with raisedlips); 10 c curved (convex); 10 d toothed or ribbed; 10 e curved(concave); and 10 f trapezoid.

In the embodiments illustrated, a flexible skeleton 18/20 is provided.The flexible skeleton 18/20 is in the embodiment illustrated in FIG. 4A,a mesh skeleton 18, such as woven 5056 aluminum alloy for conductiveapplications or woven fiberglass for non-conductive applications, or asseen in FIG. 4B, may be seen to be a non-mesh, flexible solid fabric 20,such as polytetrafluoroethylene (PTFE) or any suitable material.

In either form of flexible skeleton 18/20, it is seen that the skeletalmember is usually substantially encapsulated in the resilient body 12and may add strength to the gasket as well as integrity between portions14/16 as, seen in the illustrations, the skeletons 18/20 typicallyextend substantially throughout first portion 14 and typically, at leastpartially, into perimeter or second portion 16.

Turning to FIGS. 4A and 4B, it is seen that the first embodiment ofApplicants' device provides a relatively narrow second portion 16 incross-section 24A, at least compared to the first portion, which secondportion 16 may have a width of about 75 to about 250 mil. As set forthabove, in embodiment 10 a, the pre-compression thickness of first andsecond portions is the same, typically about 55 mil (range 25-100 mil).The other embodiments may have similar or different dimensions.

It is seen that the embodiment 10 a illustrated in FIGS. 4A-4D (or anyother embodiment) may take, positionally, one of the three locationswith respect to the pre-compression of the gasket adjacent theworkpiece. In FIGS. 4B, it is seen that improved gasket 10 a may bedimensioned, for example, die cut or molded, such that the outer edge ofthe second portion 16 is vertically aligned with the outer edge of theworkpiece, such as the outer edge of an aircraft antenna, attached to abase which may represent the fuselage of the aircraft.

In FIG. 4B, the cut of the gasket with respect to the workpiece will becalled straight or regular cut. However, in 4C it may be seen that body12, typically second portion 18 thereof and, optionally, skeleton 18/20extends pre-compression slightly beyond the outer edge of the workpieceof the gasket. The gasket of FIG. 4C may be termed “overcut.” Turning toFIG. 4D, an “undercut” gasket may be seen wherein the outer edge of theouter perimeter portion 16 and skeleton 18/20 does not reach,pre-compression, the outer edge of the workpiece.

The straight or regular cut gasket may be desired where there is only aslight bulge desired, post-compression, of the gasket at the workpieceperimeter. On the other hand, a slight overcut gasket may be provided toimprove the aesthetics of the sealing adjacent the workpiece base andouter perimeter area see in FIG. 4C.

In FIGS. 4E and 4F, undercut gasket 10 a may be used for a number ofreasons, including the ability to leave a slight gap post-compressionfor the insertion of a second material or a second gasket 25, bead or anO-ring or the like in the gap G created between the workpiece and Base(outer edge) post-compression.

FIGS. 4E and 4F illustrate the embodiment of Applicants' device using anundercut pre-cured gasket 10 a, which may be a gasket comprised of apre-cured sticky gasket 10 g of either the single or dual firmness. Itis undercut and even under compression may leave a small gap G, that is,a recess back from the outer edge of the workpiece. Applicants mayprovide a pre-cured, preformed elastomeric second gasket 25. Secondgasket 25 is configured to lay adjacent the outer perimeter of pre-curedgasket 10 a. Workpiece is placed under slight compression and an elasticUV resistant gasket 25 is urged at least partially into gap G. Furthercompression may be applied to allow some of the body 12 to be squeezedup to the inner boundaries of undercut gasket 10 a and also allow theouter edge of second gasket 25 to protrude from gap G as seen in FIG.4F.

In other applications, the undercut of FIG. 4D may be limited to fromseveral mil up to about 250 mil, in which case, under compression, theexpansion of the second portion 15 may move it out slightly so it isflush with the outer edge of the workpiece. In still other embodiments,the undercut may remain under either partial or full compression and aflowable curable polyurethane or other suitable material may be appliedat the gap at the undercut (see below). The applied material may itselfprovide a bead beyond the edge of the workpiece.

FIGS. 6, 8, 10, 12, and 14 illustrate additional embodiments (twothrough six) 10 b, 10 c, 10 d, 10 e, and 10 f, respectively, ofApplicants' improved gaskets, each illustrating differences in the shapeof second portion 16 may take as set forth in more detail below.

By varying the shapes of the outer edges, including the cross-sectionalshapes, in some cases a more effective seal may be provided, as may beneeded in different applications. Further, the post-compression visualaesthetics of the seal may be enhanced.

It is noted that any of the embodiments 10 a-10 f may be straight cut,undercut or overcut as needed for effective sealing and/or aestheticpurposes. Moreover, it is seen that any of the embodiments may have adifferential firmness wherein the softer first portion 14 has a first orgreater tackiness than the outer portion 16, which may be firmer andless tacky.

FIG. 6 illustrates a cross-sectional shaped perimeter 24 b of the secondflexible firmer outer portion 16 at the perimeter of the body 12 ofembodiment 10 b. Cross-section 24 b is seen to be similar tocross-section 24 a of embodiment 10 a (see FIG. 4E). Cross-section 24 ahas three generally straight sides and a common face 23 and a thicknessapproximately equal to the first portion 14. Cross-section 24 b ofembodiment 10 b (see FIG. 6) is seen to have an upper lip 26 a and alower lip 26 b extending above and below the top surface 14 a and bottomsurface 14 b of the first portion 14. Lips 26 a/26 b may extend severalmil (or typically up to about 20 mil) above the thickness of firstportion 14 defined as the distance between top surface 14 a and bottomsurface 14 b thereof. Typically the overall thickness T of the regularsided rectangle seen in cross-section 24 b is about 75 mil (range about25 mil to 100 mil) or any other suitable thickness.

FIG. 7 illustrates that a regular cut or slightly overcut embodiment 10b of Applicants' improved gasket may provide a slightly contoured orbulging profile, seen in cross-section across the outer edge of theworkpiece. Gasket 10 b is seen under compression between a workpiecewhich may be an aircraft antenna and a base which may be an aircraftfuselage.

FIGS. 8 and 9 illustrate a perimeter cross-section 24 c that is seen tobe plano-convex gasket 10 c. Here, as with the embodiments set forth in10 a/10 b, there is a common face 23 between firmer perimeter portion 16and less firm first portion 14. Here a convex section 30 covers an arctypically greater than 90° and a planar section 32 represents anextension of bottom surface 14 b. An adhesive strip 28, such as doublesided tape, may be provided along planar section 32 on this embodimentor any other embodiment, which may provide for pre-compression placementand positioning of any of the improved gaskets against either theworkpiece or the base prior to compression.

FIG. 9 illustrates one configuration that the embodiment illustrated inFIG. 8, embodiment 10 c of Applicants' improved gasket, may take undercompression between the workpiece and base. A rounded surface, inprofile, may be seen extending slightly beyond the edge of theworkpiece.

The increased thickness of the second portions, as illustrated inembodiments 10 b-10 e, are believed to, in part, provide greaterresistance to the migration of the soft material of first portion 14 andthe prevention of overrun outside the outer perimeter of Applicants'dual firmness or composite gasket.

In FIG. 10, illustrating embodiment 10 d, a ribbed toothed surface 34 isprovided as seen in cross-section 24 d, as either an upper or a lowersurface of the perimeter portion 16 (ribbed toothed upper surfaceshown). The toothed upper surface may help prevent creep or overrun ofthe material comprising the first portion 14 as it provides ridges thatwill flatten somewhat under compression. Moreover, improved gasket 10 dmay include an upstanding wall portion 36 may be provided in the overcutarea for both aesthetic and creep prevention. In FIG. 11, it is seen howouter walled portion 36 may be contoured to fit snugly adjacent theouter perimeter of the workpiece. The cross-sectional view seen in FIG.10 may be termed a toothed-wall.

Turning to FIGS. 12 and 13, yet another embodiment 10 e of Applicants'improved gasket is illustrated. Embodiment 10 e may be seen to provide aperimeter portion 16 that is multi-concave in cross-section 24 e, herehaving concave top and bottom walls and, optionally, a concave outerwall. This may provide for a slight concavity to the post-compressionshape and sealing against the surface of the workpiece as illustrated inFIG. 13.

FIGS. 14 and 15 illustrate the use of double adhesive strip 26 on a topwall of perimeter portion 16 and another embodiment 10 f with a shapedcross-section 24 f, here having a trapezoid (parallelogram) orquadrilateral shape with the face opposite common face 23 being slanted,typically outward from the top to bottom. While the thickness of outerportion 16 is illustrated to be the same as inner portion 14, outerportion 16 may be thicker. As in other embodiments, the embodiment 10 fof Applicants' improved gasket may be either straight cut, undercut orslightly overcut. In FIG. 15, embodiment 10 f is illustrated undercompression.

FIGS. 16A thru 21B illustrate methods of preparing Applicants' variousembodiments of their improved gasket.

FIGS. 16A and 16B illustrate a cross-sectional view in which a two-piecemold or multi-piece mold 50 is provided for embodiment 10 a, whereinmulti-piece mold 50 is defined by a top divider 52 and a bottom divider54, with a gap 56 therebetween for the skeleton to protrude through. Thetwo separate pieces are provided in a base 55 providing an upstandingbottom divider 54 and an outside wall 57. A second piece may include topdivider 52, which along with bottom divider 54, will be typically verythin metal, which may be either solid or perforated to allow flow of thefirst material comprising first portion 14 and a second materialproviding the second portion 16 thereof, so there may be interminglingduring cure.

A cap 53, including top divider 52, may be removed and, to start theprocedure, skeleton 18/20 is placed across base 53 supported on the topedge of bottom divider 54 and extending partway past bottom divider 54into space that will be filled with the second (firmer) composition. Thefirst composition may then be poured pre-mixed in the snout S of theapplicator A in known ways, and allowed to self-level to the desiredheight, here H 14 and H 16 being equal. Following curing, cap 53 and topdivider 52 are removed leaving the cross-section illustrated in FIG.15B. At this point, applicator A, this time having second material, acomposition firmer than the composition of the first material, will beapplied to level H 16. When this cures, the gasket 10 a can be carefullyremoved and is ready for use.

FIGS. 17A and 17B illustrate similar procedures, which can be used whenH 16 is greater than H 14, for embodiment 10 b. Here it will be seenthat top divider 52, bottom divider 54, and gap 56 add up to a height ofabout H 16. Here, perimeter 16 can be poured first, allowed to cure and,after removal of top divider 16, the first portion 14 can be injected toa height of approximately H 14 leaving, when cured, a gasketsubstantially resembling embodiment 10 b with a cross-section 24 b.

FIGS. 18A and 18B illustrate a manner in which a two-piece base 55having lower portion 55 a and upper portion 55 b may be joined togetherto provide the curved section of embodiment 10C. Here, outer portion 16may be injected first and then inner portion 14 may be injected to thedesired height. Portion 55 b of base 55 may be removed for ease ofremoval of the gasket embodiment 10 c having cross-section 24 cfollowing curing of both portions 14/16.

FIGS. 19A and 19B also disclose the two-step method and two piece moldsof the previous embodiment providing a first pouring or injecting of oneof the first or second portions when the top divider and bottom dividerare adjacent one another and a second pouring of the other or first orsecond portion following the removal of the top divider. Here, it isseen that base 55 is provided with a surface that is shaped to conformto the desired shape of outer portion 16, here, see 24 d of embodiment10 d.

FIGS. 20A, 20B, 21A, and 21B also illustrate a manner of configuring themold, typically in two pieces, to conform to the desired end producthaving a specifically configured first portion 14 and a second portion16 of a different, harder consistency.

FIG. 20A illustrates top divider and bottom divider working together toprovide a perimeter region in which a flowable, pre-cured mix can beinjected to provide a proper or suitable shape to the firmer portion,while allowing some of the skeleton to extend into the perimeterportion. Once the perimeter portion has cured top divider 52 may beremoved and, as set forth in FIG. 20B, the less sticky or less firmpre-cured mix may be injected and allowed to cure.

FIG. 21 illustrates a similar process, but the top divider is not neededto provide full coverage as the moldable material may self-level asindicated.

With reference to FIGS. 22-27, a gasket 10 g is represented. This gasketmay be any of the dual tackiness and/or firmness as set forth herein.However, with the disclosure that follows, it is pointed out that thegasket 10 g may be any of the gaskets of the prior art, but withfeatures set herein, including exposed or non-exposed skeleton andundercut or straight cut features. Furthermore, a bead 58 will beapplied to the outer edge of body 12. The bead is not cured, and willcure in place after the (cured) gasket is between the workpiece andbase. Moreover, the bead is typically forced into a gap G left b thebody of the gasket not reaching the edge of the workpiece. The skeleton18/20 may or may not extend beyond the outer edge of the body. When itdoes, it will help bead 58 adhere to the gasket.

FIG. 22 illustrates the preparation of a gasket 10 g, wherein thegasket's skeleton 18/20 extends beyond the outer edges of body 12.Furthermore, in FIG. 23, Applicants illustrate that gasket 10 g, whichmay be either of a single or dual tackiness as set forth above, may beundercut with respect to the workpiece Typically, however, the bareedges of skeleton 18/20 will go up to the edge of the workpiece asillustrated in FIG. 23.

In FIG. 24, gasket 10 g is seen under sufficient compression such thatsome of the material comprising body 12 will ooze out to about the edgeof the workpiece.

FIG. 24A illustrates an embodiment of the undercut exposed skeletongasket embodiment 10 g, which may be either single or dual tackiness,wherein under some or complete compression material of body 12 does notreach the outer edge of the workpiece. Here, as with the previousembodiment, there is exposed or bare skeleton 18/20 in gap G, but evenunder compression still leaves some of the skeleton exposed.

In FIG. 24B, any of the early embodiments are illustrated in an undercutconfiguration (no exposed skeleton) when a gap G is left even aftercompression (either partial or complete) of the workpiece against thebase.

Turning to FIG. 25, it is seen that the embodiment of FIG. 24, whereinunder compression body material 12 squeezes up to about the edge of theworkpiece, bead 58 may be applied through snout S of an applicatorapplying a curable mix that will cure after application. The materialused for the bead will typically be UV resistant and bond to the body 12of the gasket 10 g. One such curable mix from which bead may be made ofa polysulfide which has suitable adhesion to a polyurethane body andwhich is somewhat UV resistant.

FIG. 26 illustrates the use of a shaping tool ST prior to curing of thebead to shape and to remove excess bead material from the contactbetween the workpiece, the base, and the edge of gasket 10 g.

Turning back to FIGS. 25A and 25B, it is seen that bead 58 may beapplied to the gap G when an undercut gasket is provided that has anexposed skeleton 18/20 as in FIG. 25A. The term “undercut” here is usedto describe an undercut of the body material 12 where, even undercompression, the body material leaves a gap between it and the edge ofthe workpiece. Such a gap is then filled after the workpiece and gasketare placed on the base (see FIG. 25), with a suitable bead material tobe cured with the workpiece in place. This bead material may be shapedas illustrated in FIG. 26 or otherwise formed into a suitable shape. InFIG. 25B, undercut refers to the gasket under compression, whereinneither the skeletal material nor the body reaches the edge of theworkpiece. Here the gap is filled with the bead 58 (which may extendbeyond the edge of the workpiece) as in FIGS. 25 and 25A, and may beshaped.

FIG. 27 illustrates the final cured bead 58 adjacent to and sealedagainst gasket 10 g, workpiece WP, and the base. The bead is typicallyfirmer and/or less tacky than body 12.

All dimensions set forth herein are approximate and the ranges may bevaried to suit specific applications.

Although the invention has been described with reference to a specificembodiment, this description is not meant to be construed in a limitingsense. On the contrary, various modifications of the disclosedembodiments will become apparent to those skilled in the art uponreference to the description of the invention. It is thereforecontemplated that the appended claims will cover such modifications,alternatives, and equivalents that fall within the true spirit and scopeof the invention.

1. A method for making an environmental seal between a first aircraft part and a second aircraft part with a gasket, the gasket having a unitary skeleton having multiple openings and an elastomeric, polymer body with a first firmness defining a first encapsulated section, wherein a first skeleton portion of the skeleton is encapsulated with the polymer in a cured condition, the gasket having a second unencapsulated skeleton portion of the skeleton which is bare and not encapsulated, the method comprising: encapsulating the second skeleton portion of the gasket in an uncured, two-part polymer mix; and allowing the uncured mix to cure; wherein the uncured mix cures to form a second encapsulated section having a different hardness than the first firmness.
 2. The method of claim 1, wherein the skeleton is a woven mesh.
 3. The method of claim 1, wherein the woven mesh is electrically conductive.
 4. The method of claim 1, wherein the woven mesh is electrically non-conductive.
 5. The method of claim 1, wherein the second encapsulated section is a perimeter section of the gasket.
 6. The method of claim 1, wherein the second encapsulated section is a non-perimeter section of the gasket.
 7. The method of claim 5, wherein the perimeter is an outer perimeter.
 8. The method of claim 5, wherein the perimeter is an inner perimeter.
 9. The method of claim 1, wherein at least one of the encapsulated sections comprise a polyurethane polymer and the perimeter is a polysulfide.
 10. The method of claim 9, wherein the polyurethane polymer is a gel.
 11. The method of claim 10, wherein the gel is tacky in a cured condition.
 12. The method of claim 1, further including the step of providing a mold configured to separate the second skeleton portion from the first skeleton portion.
 13. The method of claim 12, wherein the encapsulating step includes the step of injecting, just after mixing the uncured two-part polymer mix, into the mold onto the second skeleton portion.
 14. The method of claim 13, wherein the second skeleton portion is a non-perimeter section.
 15. The method of claim 13, wherein the second skeleton portion is a perimeter section.
 16. The method of claim 12, wherein the mold is a two-piece mold.
 17. The method of claim 16, wherein the two piece mold is configured to separate the first skeleton portion from the second skeleton portion.
 18. The method of claim 16, wherein the two-piece mold includes one piece configured to shape a perimeter of the seal.
 19. The method of claim 18, wherein the configured one piece is configured to shape the perimeter so that the perimeter has a greater thickness than a thickness of any part of the non-perimeter part.
 20. The method of claim 1, wherein the uncured two-part polymer mix is self-leveling.
 21. A method of making a seal between a first aircraft part and a second aircraft part, the first aircraft part having a perimeter defining a perimeter shape, the two aircraft parts having a gap therebetween the method including the steps of: providing a gasket with a polymer body and a skeleton with the skeleton having a first skeleton portion encapsulated in the polymer body and a second skeleton portion comprising a non-encapsulated, bare skeleton, the non-encapsulated, bare portion having an outer edge configured to the perimeter shape of the first aircraft part; placing the gasket in the gap between the two aircraft parts such that the outer edge of the non-encapsulated portion is adjacent the perimeter of the first aircraft part and at least part of the gasket is touching the two parts; applying a two-part uncured polymer mix to the second skeleton portion of the gasket; and allowing the applied mix to cure; wherein the mix cures to a firmness different from the firmness of the cured polymer body encapsulating the first portion of the skeleton.
 22. The method of claim 21, further including, after the applying step and before the allowing step is completed, the step of shaping the applied mix.
 23. The method of claim 22, wherein the shaping step is achieved with a shaping tool which has a portion that conforms to the desired shape of a perimeter of the seal.
 24. The method of claim 21, wherein the two-part, uncured polymer mix of the applying step contains a U.V. protectant component.
 25. The method of claim 21, wherein the applying step includes the step of applying the two-part, uncured polymer mix such that a portion contacts the second section of the gasket, a portion contacts the first aircraft part, a portion contacts the second aircraft part and a portion contacts none of the foregoing portion structures.
 26. The method of claim 25, wherein the applying step incudes the step of applying at least some of the uncured, two-part mix in the gap.
 27. The method of claim 26, wherein the applying step incudes the step of applying at least some of the uncured. two-part mix outside the gap.
 28. The method of claim 21, wherein the providing step and the placement steps allow the placement of the gasket in an undercut position.
 29. The method of claim 21, wherein the providing step and the placement steps allow the placement of the gasket in a straight cut position.
 30. The method of claim 21, wherein the providing step and the placement steps allow the placement of the gasket in an overcut position.
 31. The method of claim 21, wherein the skeleton of the gasket is electrically conductive.
 32. The method of claim 21, wherein the skeleton of the gasket is electrically non-conductive. 